System and Methods for Bonding a Structural Component Within a Channel of a Rail

ABSTRACT

The present disclosure provides a method for bonding a structural component to a rail. The method includes (a) positioning a bonding agent in a plurality of blind holes defined in a bottom surface of the rail, (b) positioning a spacer in each of the plurality of blind holes, (c) positioning the structural component into the channel such that the structural component rests on each spacer, wherein a first gap is defined between the structural component and the bottom surface of the rail, a second gap is defined between the structural component and a first sidewall of the rail, and a third gap is defined between the structural component and a second sidewall of the rail, and (d) injecting the bonding agent into the channel such that each of the first gap, the second gap, and the third gap includes the bonding agent.

FIELD

The present disclosure relates generally to bonding systems, and moreparticularly, to systems and methods for bonding a structural componentwithin a channel of a rail.

BACKGROUND

Traditionally, joining an aircraft canopy to a canopy rail involvesdrilling holes in both the aircraft canopy and the canopy rail, andattaching nuts, bolts, and sealers through those drilled holes tothereby secure the aircraft canopy to the canopy rail. Such a processmay be time consuming, and may result in an assembly with discontinuousforces applied to the canopy assembly. To address these potentialconcerns, a bonding agent may be used to bond the canopy to the canopyrail in place of nuts and bolts. However, such an approach may becomplicated by the fact that the bonding agent requires a minimum gapbetween the aircraft canopy and the sidewalls and bottom surface of thecanopy rail to allow the bonding agent to flow around and adhere to theaircraft canopy positioned in the canopy rail.

SUMMARY

In one aspect, a method for bonding a structural component to a rail,the rail including a bottom surface, a first sidewall extending from thebottom surface, and a second sidewall extending from the bottom surfaceto thereby define a channel is described. The method includes (a)positioning a bonding agent in a plurality of blind holes defined in thebottom surface of the rail, (b) positioning a spacer in each of theplurality of blind holes, wherein each spacer has a stem and a topportion extending substantially perpendicular to the stem, and whereinthe stem of the spacer is positioned in each of the plurality of blindholes such that a longitudinal axis of the top portion of each spacer isparallel to a longitudinal axis of the channel, (c) positioning thestructural component at least partially into the channel such that thestructural component rests on each spacer, wherein a first gap isdefined between the structural component and the bottom surface of therail, wherein a second gap is defined between the structural componentand the first sidewall of the rail, and wherein a third gap is definedbetween the structural component and the second sidewall of the rail,and (d) injecting the bonding agent into the channel such that each ofthe first gap, the second gap, and the third gap includes the bondingagent to thereby bond the structural component to the rail.

In another aspect, a system for bonding a structural component to a railis described. The system includes (a) a rail including a bottom surface,a first sidewall extending from the bottom surface, and a secondsidewall extending from the bottom surface to thereby define a channel,wherein the rail further includes a plurality of blind holes defined inthe bottom surface, (b) a plurality of spacers each including a stem anda top portion extending substantially perpendicular to the stem, andwherein the stem of a given spacer of the plurality of spacers isconfigured to be positioned in each of the plurality of blind holes suchthat a longitudinal axis of the top portion of each spacer is parallelto a longitudinal axis of the channel, and (c) a structural componentconfigured to be positioned at least partially into the channel suchthat the structural component rests on the top portion of the pluralityof spacers.

In yet another aspect, another method for bonding a structural componentto a rail, the rail including a bottom surface, a first sidewallextending from the bottom surface, and a second sidewall extending fromthe bottom surface to thereby define a channel is described. The methodincludes (a) positioning a bonding agent in a plurality of blind holesdefined in the bottom surface of the rail, (b) positioning a spacer ineach of the plurality of blind holes, wherein each spacer has a stem anda top portion extending substantially perpendicular to the stem, andwherein the stem of the spacer is positioned in each of the plurality ofblind holes such that a longitudinal axis of the top portion of eachspacer is parallel to a longitudinal axis of the channel, (c)positioning the structural component at least partially into the channelsuch that the structural component rests on each spacer, wherein a firstgap is defined between the structural component and the bottom surfaceof the rail, wherein a second gap is defined between the structuralcomponent and the first sidewall of the rail, and wherein a third gap isdefined between the structural component and the second sidewall of therail, (d) positioning a first plurality of removable spacers between thefirst sidewall of the rail and the structural component, (e) positioninga second plurality of removable spacers between the second sidewall ofthe rail and the structural component, (f) sealing an upper edge of thefirst sidewall of the rail to the structural component whilesimultaneously removing the first plurality of removable spacers, (g)sealing an upper edge of the second sidewall of the rail to thestructural component while simultaneously removing the second pluralityof removable spacers, (h) injecting the bonding agent into a firstthrough hole of a plurality of through holes in the bottom surface ofthe rail such that the bonding agent exits an adjacent through hole ofthe plurality of through holes, (i) sealing the first through hole, (j)repeating the previous two steps such that each of the plurality ofthrough holes have been injected with the bonding agent and each of thefirst gap, the second gap, and the third gap includes the bonding agentto thereby bond the structural component to the rail.

The features, functions, and advantages that have been discussed can beachieved independently in various examples or may be combined in yetother examples further details of which can be seen with reference tothe following description and figures.

BRIEF DESCRIPTION OF THE FIGURES

The novel features believed characteristic of the illustrative examplesare set forth in the appended claims. The illustrative examples,however, as well as a preferred mode of use, further objectives anddescriptions thereof, will best be understood by reference to thefollowing detailed description of an illustrative examples of thepresent disclosure when read in conjunction with the accompanyingfigures.

FIG. 1 is a block diagram of an example system.

FIG. 2A is a perspective view of an example spacer that can be used inthe system shown in FIG. 1.

FIG. 2B is a bottom perspective view of the spacer of FIG. 2A.

FIG. 3A is perspective view of an example spacer positioned in a channelof a rail in the system of FIG. 1.

FIG. 3B is a section A-A cross-section view of the spacer and rail ofFIG. 3A with a structural component positioned in the channel of therail.

FIG. 4A is a flowchart of an example method for bonding a structuralcomponent to a rail using the system of FIGS. 1 to 3B.

FIG. 4B is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 4A.

FIG. 4C is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 4A.

FIG. 4D is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 4A.

FIG. 4E is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 4A.

FIG. 4F is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 4A.

FIG. 5A is a flowchart of another example method for bonding astructural component to a rail using the systems of FIGS. 1 to 3B.

FIG. 5B is a flowchart of a method, which is a continuation of themethod for bonding a structural component to a rail using the systems ofFIGS. 1 to 3B shown in FIG. 5A.

DETAILED DESCRIPTION

The examples described herein provide an improved spacer andcorresponding method of use when bonding a structural component (e.g.,aircraft canopy) to a corresponding structural channel (e.g., canopyrail). Within examples, a system for bonding a structural component to arail is described herein. More specifically, as described herein,joining a structural component to a rail using a bonding compound canassure an airtight seal and uniform distribution of loads and stressesalong that fitting.

Accordingly, the improved system described herein can enable joining ofa structural component to a corresponding rail using a bonding componentwhile assuring that the structural component seats into the rail withuniform pre-determined fit and structural integrity. In particular, thesystem described herein includes a plurality of spacers each including astem and a top portion extending substantially perpendicular to thestem. The stem of a given spacer of the plurality of spacers isconfigured to be positioned in each of a plurality of blind holes in abottom surface of the rail such that a longitudinal axis of the topportion of each spacer is parallel to a longitudinal axis of a channelof the rail. The structural component is configured to be positioned atleast partially into the channel such that the structural componentrests on the top portion of the plurality of spacers. When thestructural component is positioned on the top portion of the pluralityof spacers, a first gap is defined between the structural component andthe bottom surface of the rail, a second gap is defined between thestructural component and a first sidewall of the rail, and a third gapis defined between the structural component and a second sidewall of therail.

Various other features of the example systems discussed above, as wellas methods for using these systems, are also described hereinafter withreference to the accompanying figures. Illustrative, non-exhaustiveexamples, which may or may not be claimed, of the subject matteraccording the present disclosure are provided below.

With reference to the Figures, FIG. 1 illustrates an example system 100for bonding a structural component 102 to a rail 104. As shown in FIG.1, the system 100 includes a rail 104 including a bottom surface 106, afirst sidewall 108 extending from the bottom surface 106, and a secondsidewall 110 extending from the bottom surface 106 to thereby define achannel 112. The rail 104 further includes a plurality of blind holes114 defined in the bottom surface 106. The system 100 also includes aplurality of spacers 116 each including a stem 118 and a top portion 120extending substantially perpendicular to the stem 118. The stem 118 of agiven spacer of the plurality of spacers 116 is configured to bepositioned in each of the plurality of blind holes 114 such that alongitudinal axis of the top portion 120 of each spacer 116 is parallelto a longitudinal axis of the channel 112. In one example, each of theplurality of spacers 116 are a different color than the rail 104 suchthat the plurality of spacers 116 are easily distinguishable from therail 104. The system 100 also includes a structural component 102configured to be positioned at least partially into the channel 112until the structural component 102 rests on the top portion 120 of theplurality of spacers 116.

The plurality of spacers 116 may be made of a material and a thicknessthat will bear the weight transferred from the structural component 102to the rail 104. In one example, each of the plurality of spacers 116comprises a first material, and the structural component 102 comprises asecond material that is different than the first material. In oneexample, the first material is softer than the second material. As usedherein, the “softness” of the first material and the second material maybe defined by a hardness scale value (e.g., Rockwell or Shore hardness),a Vickers hardness value, a compression, a durability, or a plasticdeformation. Such an arrangement may help prevent damage to thestructural component 102 when it is positioned on the plurality ofspacers 116. However, the first material should be sufficiently strongto avoid noticeable deformation under the weight of the structuralcomponent 102. The first material of the plurality of spacers 116 mayinclude any material that is compatible with the rail 104, thestructural component 102, and the bonding agent 103 used to secure thestructural component 102 to the rail 104.

The vertical height of the top of each of the plurality of spacers 116determines the space between the bottom surface 106 of the rail 104 andthe bottom of the structural component 102. Such a vertical height maybe selected based on the particular structural component 102 andparticular rail 104 into which the structural component 102 ispositioned.

The top portion 120 of each of the plurality of spacers 116 includes atop surface 124, a bottom surface 126 opposite the top surface 124, afirst side surface 128, and a second side surface 130 opposite the firstside surface 128. In one example, as shown in FIGS. 2A-2B, each of thetop surface 124, the bottom surface 126, the first side surface 128, andthe second side surface 130 are substantially flat. The substantiallyflat top surface 124 helps to ensure a solid fit with the structuralcomponent 102, while the substantially flat bottom surface 126 helps toensure a snug fit with the bottom surface 106 of the rail 104. The firstside surface 128 and second side surface 130 may be substantially flatto ensure that the bonding agent 103 can flow around the top surface 124of the spacer 116, as discussed in additional detail below with respectto FIGS. 4 and 5.

In one example, the bottom surface 106 of the rail 104 further includesa plurality of through holes 132 interspaced between the plurality ofblind holes 114 on the bottom surface 106 of the rail 104, as shown inFIG. 3A. As used herein, “interspaced” means occupying a space betweentwo things. For example, the plurality of through holes 132 areinterspaced between the plurality of blind holes 114 on the bottomsurface 106 of the rail 104 such that the bottom surface 106 alternatesbetween a though hole 132 and a blind hole 114. The plurality of blindholes 114 and plurality of though holes 132 may be evenly interspaced,or may be unevenly interspaced such that there is a different distancebetween adjacent holes. The plurality of through holes 132 provide alocation into which the bonding agent 103 can be injected, as discussedin addition detail below with respect to FIGS. 4 and 5.

The stem 118 of each of the plurality of spacers 116 may include a firstside 134, a second side 136 opposite the first side 134, a third side138, a fourth side 140 opposite the third side 138, and a bottom side139. The bottom side 139 may be substantially flat such that it sitsflat on the bottom surface of the blind hole 114. In one example, thefirst side 134 and the second side 136 are substantially flat and areparallel to the longitudinal axis of the channel 112, and the third side138 and the fourth side 140 have a radius of curvature 142 correspondingto a diameter 115 of each of the plurality of blind holes 114. In suchan example, the rounded third side 138 and fourth side 140 of the stem118 of each of the plurality of spacers 116 has a light to nointerference fit into each of the plurality of blind holes 114. In oneexample, the stem 118 of each of the plurality of spacers 116 is pressfit into each of the plurality of blind holes 114. In another example, abonding agent 103 is positioned into each of the plurality of blindholes 114 before inserting the stem 118 of each of the plurality ofspacers 116. In such an example, the substantially flat first side 134and second side 136 can enable excess bonding agent 103 to exit theplurality of blind holes when the stem 118 is inserted therein. Further,the substantially flat first side 134 and second side 136 can enable thebonding agent 103 to flow into the plurality of blind holes 114, furtherassuring the quality of the bond between the structural component 102and the rail 104.

The distance between the first side surface 128 and the second sidesurface 130 of the top portion 120 of each of the plurality of spacers116 may be equal to the distance between the first side 134 and thesecond side 136 of the stem 118 of each of the plurality of spacers 116.Such an arrangement may help ensure that the bonding agent 103 can flowboth around the top portion 120 of each of the plurality of spacers 116as well as into each of the plurality of blind holes 114 in the bottomsurface 106 of the rail 104.

The plurality of blind holes 114 are drilled with pre-determined spacingsuch that when the plurality of spacers 116 are positioned in thecorresponding plurality of blind holes 114, the plurality of spacers 116satisfy fit and load bearing requirements to support the structuralcomponent 102 positioned thereon. When the structural component 102 ispositioned on the top portion 120 of the plurality of spacers 116, afirst gap 144 is defined between the structural component 102 and thebottom surface 106 of the rail 104, a second gap 146 is defined betweenthe structural component 102 and a first sidewall 108 of the rail 104,and a third gap 148 is defined between the structural component 102 anda second sidewall 110 of the rail 104. The various gap sizes may bedetermined based on the width of the distance between the first sidewall108 and the second sidewall 110, the width of the structural component102, and the viscosity of the bonding agent 103 used to bond thestructural component 102 to the rail 104.

In one example, the system 100 further includes a first plurality ofremovable spacers 150 configured to be removably positioned between thefirst sidewall 108 of the rail 104 and the structural component 102. Thesystem 100 may further include a second plurality of removable spacers152 configured to be removably positioned between the second sidewall110 of the rail 104 and the structural component 102. The firstplurality of removable spacers 150 and the second plurality of removablespacers 152 may help center the structural component 102 between thefirst sidewall 108 and the second sidewall 110 of the rail 104 beforethe bonding agent 103 is injected into the channel 112. As the bondingagent 103 is injected into the channel 112, the first plurality ofremovable spacers 150 and the second plurality of removable spacers 152may be removed.

In one particular example, the structural component 102 comprises anaircraft canopy, and the rail 104 comprises a canopy rail. However, theuse of the system 100 described above is not limited to aircraftcanopies. Instead, the system 100 described above can be used in anycircumstance where it is necessary to bond a structural component to andwithin a channel defined by a rail having a bottom surface and twoopposing sidewalls.

FIG. 4A is a block diagram of an example method for bonding a structuralcomponent 102 to a rail 104. As discussed above, the rail 104 includes abottom surface 106, a first sidewall 108 extending from the bottomsurface 106, and a second sidewall 110 extending from the bottom surface106 to thereby define a channel 112. Method 200 shown in FIG. 4Apresents an example of a method that could be used to assemble thesystem 100 discussed above in relation to FIGS. 1-3B, as an example.Method 200 includes one or more operations, functions, or actions asillustrated by one or more of blocks 202-208. In one example, anaircraft component supplier can manufacture or deliver the structuralcomponent 102 and/or the rail 104 to an end user such as an aircraftmanufacturer. The aircraft manufacturer could then perform the actionsrecited in blocks 202-208 below. Although the blocks are illustrated ina sequential order, these blocks may also be performed in parallel,and/or in a different order than those described herein. Also, thevarious blocks may be combined into fewer blocks, divided intoadditional blocks, and/or removed based upon the desired implementation.

Initially, at block 202, the method 200 includes positioning a bondingagent 103 in a plurality of blind holes 114 defined in the bottomsurface 106 of the rail 104. The bonding agent 103 may be selected basedon the particular structural component 102 that will be bonded to aparticular rail 104. At block 204, the method 200 includes positioning aspacer 116 in each of the plurality of blind holes 114. As discussedabove, each spacer 116 has a stem 118 and a top portion 120 extendingsubstantially perpendicular to the stem 118 to form a t-shape. The stem118 of the spacer 116 is positioned in each of the plurality of blindholes 114 such that a longitudinal axis of the top portion 120 of eachspacer 116 is parallel to a longitudinal axis of the channel 112. In oneexample, positioning a spacer 116 in each of the plurality of blindholes 114 comprises positioning each spacer 116 such that thelongitudinal axis of the top portion 120 of each spacer 116 ispositioned in a flow direction of the bonding agent 103 when the bondingagent 103 is injected into the channel 112. As such, each spacer 116 isaligned with the injection flow path of the bonding agent 103 to therebyreduce the impact the spacer 116 has on the flow of the bonding agent103.

At block 206, the method 200 includes positioning the structuralcomponent 102 at least partially into the channel 112 such that thestructural component 102 rests on each spacer 116. As discussed above, afirst gap 144 is defined between the structural component 102 and thebottom surface 106 of the rail 104, a second gap 146 is defined betweenthe structural component 102 and the first sidewall 108 of the rail 104,and a third gap 148 is defined between the structural component 102 andthe second sidewall 110 of the rail 104.

At block 208, the method 200 includes injecting the bonding agent 103into the channel 112 such that each of the first gap 144, the second gap146, and the third gap 148 includes the bonding agent 103 to therebybond the structural component 102 to the rail 104. In particular, thebonding agent 103 cures for a time period to ensure that the structuralcomponent 102 is permanently bonded to the rail 104.

In one example, as shown in FIG. 4B, at block 210 the method 200 furtherincludes sealing an upper edge of the first sidewall 108 of the rail 104to the structural component 102. At block 212, the method 200 furtherincludes sealing an upper edge of the second sidewall 110 of the rail104 to the structural component 102. In one particular example, sealingthe upper edge of the first sidewall 108 of the rail 104 and thestructural component 102 comprises applying a first fillet seal, andsealing the upper edge of the second sidewall 110 of the rail 104 andthe structural component 102 comprises applying a second fillet seal. Asused herein, applying a seal may involve the steps of applying a sealantto a surface and shaping at least a portion of the sealant (while thesealant is wet or uncured) into a fillet or curved surface. Othersealing methods are possible as well.

In one example, the bonding agent 103 is injected into the channel 112prior to positioning the structural component 102 at least partiallyinto the channel 112 such that the structural component 102 rests oneach spacer 116. In such an example, as shown in FIG. 4C, at block 214the method 200 may further include removing excess bonding agent 103above an upper edge of the first sidewall 108 of the rail 104 and abovean upper edge of the second sidewall 110 of the rail 104.

In another example, the step of injecting the bonding agent 103 into thechannel 112 includes injecting the bonding agent 103 into the second gap146 between the structural component 102 and the first sidewall 108 ofthe rail 104, and injecting the bonding agent 103 into the third gap 148between the structural component 102 and the second sidewall 110 of therail 104.

In another example, as shown in FIG. 4D, at block 216 the method 200further includes positioning a first plurality of removable spacers 150between the first sidewall 108 of the rail 104 and the structuralcomponent 102. At block 218, the method 200 further includes positioninga second plurality of removable spacers 152 between the second sidewall110 of the rail 104 and the structural component 102. At block 220, themethod 200 further includes removing the first plurality of removablespacers 150 and the second plurality of removable spacers 152 prior toinjecting the bonding agent 103 into the channel 112. As discussedabove, the first plurality of removable spacers 150 and the secondplurality of removable spacers 152 may help center the structuralcomponent 102 between the first sidewall 108 and the second sidewall 110of the rail 104 before the bonding agent 103 is injected into thechannel 112.

In one example, the bottom surface 106 of the rail 104 includes aplurality of through holes 132. In such an example, as shown in FIG. 4E,at block 222 the method 200 further includes sealing an upper edge ofthe first sidewall 108 of the rail 104 to the structural component 102.At block 224, the method 200 further includes sealing an upper edge ofthe second sidewall 110 of the rail 104 to the structural component 102.At block 226, the method 200 further includes injecting the bondingagent 103 into a first through hole of the plurality of through holes132 such that the bonding agent 103 exits an adjacent second throughhole of the plurality of through holes 132. At block 228, the method 200further includes sealing the first through hole. At block 230, themethod 200 further includes repeating the steps from blocks 226 and 228such that each of the plurality of through holes 132 have been injectedwith the bonding agent 103 and each of the first gap 144, the second gap146, and the third gap 148 includes the bonding agent 103. The pluralityof through holes 132 may be interspaced evenly between the plurality ofblind holes 114 on the bottom surface 106 of the rail 104.

In one particular example, sealing the upper edge of the first sidewall108 of the rail 104 to the structural component 102 comprises applying afirst dam seal between the upper edge of the first sidewall 108 of therail 104 and the structural component 102, and sealing an upper edge ofthe second sidewall 110 of the rail 104 to the structural component 102comprises applying a second dam seal between the upper edge of thesecond sidewall 110 of the rail 104 and the structural component 102. Inanother example, as shown in FIG. 4F, at block 232 the method 200further includes applying a first fillet seal between the upper edge ofthe first sidewall 108 of the rail 104 and the structural component 102.At block 234, the method 200 further includes applying a second filletseal between the upper edge of the second sidewall 110 of the rail 104and the structural component 102.

FIG. 5A is a block diagram of another example method for bonding astructural component 102 to a rail 104. As discussed above, the rail 104includes a bottom surface 106, a first sidewall 108 extending from thebottom surface 106, and a second sidewall 110 extending from the bottomsurface 106 to thereby define a channel 112. Method 300 shown in FIG. 5Apresents an example of a method that could be used to assemble thesystem 100 discussed above in relation to FIGS. 1-3B, as an example.Method 300 includes one or more operations, functions, or actions asillustrated by one or more of blocks 302-320. In one example, anaircraft component supplier can manufacture or deliver the structuralcomponent 102 and/or the rail 104 to an end user such as an aircraftmanufacturer. The aircraft manufacturer could then perform the actionsrecited in blocks 302-320 below. Although the blocks are illustrated ina sequential order, these blocks may also be performed in parallel,and/or in a different order than those described herein. Also, thevarious blocks may be combined into fewer blocks, divided intoadditional blocks, and/or removed based upon the desired implementation.

Initially, at block 302, the method 300 includes positioning a bondingagent 103 in a plurality of blind holes 114 defined in the bottomsurface 106 of the rail 104. At block 304, the method 300 includespositioning a spacer 116 in each of the plurality of blind holes 114,where each spacer has a stem 118 and a top portion 120 extendingsubstantially perpendicular to the stem 118, and where the stem 118 ofthe spacer 116 is positioned in each of the plurality of blind holes 114such that a longitudinal axis of the top portion 120 of each spacer 116is parallel to a longitudinal axis of the channel 112. At block 306, themethod 300 includes positioning the structural component 102 at leastpartially into the channel 112 such that the structural component 102rests on each spacer 116, where a first gap 144 is defined between thestructural component 102 and the bottom surface 106 of the rail 104, asecond gap 146 is defined between the structural component 102 and thefirst sidewall 108 of the rail 104, and a third gap 148 is definedbetween the structural component 102 and the second sidewall 110 of therail 104.

At block 308, the method 300 further includes positioning a firstplurality of removable spacers 150 between the first sidewall 108 of therail 104 and the structural component 102. At block 310, the method 300further includes positioning a second plurality of removable spacers 152between the second sidewall 110 of the rail 104 and the structuralcomponent 102. At block 312, the method 300 further includes sealing anupper edge of the first sidewall 108 of the rail 104 to the structuralcomponent 102 while simultaneously removing the first plurality ofremovable spacers 150. At block 314, the method 300 further includessealing an upper edge of the second sidewall 110 of the rail 104 to thestructural component 102 while simultaneously removing the secondplurality of removable spacers 152. As discussed above, the previous twosteps (312-314) may comprise a dam seal or other type of seal to createa closed cavity in the channel 112.

At block 316, the method 300 further includes injecting the bondingagent 103 into a first through hole of a plurality of through holes 132in the bottom surface 106 of the rail 104 such that the bonding agent103 exits an adjacent through hole of the plurality of through holes132. At block 318, the method 300 includes sealing the first throughhole. At block 320, the method 300 includes repeating the previous twosteps (316-318) such that each of the plurality of through holes 132have been injected with the bonding agent 103 and each of the first gap144, the second gap 146, and the third gap 148 includes the bondingagent 103 to thereby bond the structural component 102 to the rail 104.

In one example, as shown in FIG. 5B, at block 322 the method 300 furtherincludes applying a first fillet seal between the upper edge of thefirst sidewall 108 of the rail 104 and the structural component 102. Atblock 324, the method 300 may further include applying a second filletseal between the upper edge of the second sidewall 110 of the rail 104and the structural component 102.

In the above description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts weredescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

In FIGS. 4A-5B, referred to above, the blocks may represent operationsand/or portions thereof and lines connecting the various blocks do notimply any particular order or dependency of the operations or portionsthereof. It will be understood that not all dependencies among thevarious disclosed operations are necessarily represented. FIGS. 4A-5Band the accompanying disclosure describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one example” means that one or more feature,structure, or characteristic described in connection with the example isincluded in at least one implementation. The phrase “one example” invarious places in the specification may or may not be referring to thesame example.

As used herein, a system, apparatus, device, structure, article,element, component, or hardware “configured to” perform a specifiedfunction is indeed capable of performing the specified function withoutany alteration, rather than merely having potential to perform thespecified function after further modification. In other words, thesystem, apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware which enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

As used herein, with respect to measurements, “about” and“substantially” each means +/−5%.

As used herein, a “blind hole” is a hole that is recessed in a surfacebut does not extend through that surface.

The description of the different advantageous arrangements has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the examples in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageous examplesmay provide different advantages as compared to other advantageousexamples. The example or examples selected are chosen and described inorder to best explain the principles of the examples, the practicalapplication, and to enable others of ordinary skill in the art tounderstand the disclosure for various examples with variousmodifications as are suited to the particular use contemplated.

what is claimed is:
 1. A method for bonding a structural component to arail, the rail including a bottom surface, a first sidewall extendingfrom the bottom surface, and a second sidewall extending from the bottomsurface to thereby define a channel, the method comprising: positioninga bonding agent in a plurality of blind holes defined in the bottomsurface of the rail; positioning a spacer in each of the plurality ofblind holes, wherein each spacer has a stem and a top portion extendingsubstantially perpendicular to the stem, and wherein the stem of thespacer is positioned in each of the plurality of blind holes such that alongitudinal axis of the top portion of each spacer is parallel to alongitudinal axis of the channel; positioning the structural componentat least partially into the channel such that the structural componentrests on each spacer, wherein a first gap is defined between thestructural component and the bottom surface of the rail, wherein asecond gap is defined between the structural component and the firstsidewall of the rail, and wherein a third gap is defined between thestructural component and the second sidewall of the rail; and injectingthe bonding agent into the channel such that each of the first gap, thesecond gap, and the third gap includes the bonding agent to thereby bondthe structural component to the rail.
 2. The method of claim 1, furthercomprising: sealing an upper edge of the first sidewall of the rail tothe structural component; and sealing an upper edge of the secondsidewall of the rail to the structural component.
 3. The method of claim2, wherein sealing the upper edge of the first sidewall of the rail andthe structural component comprises applying a first fillet seal, andwherein sealing the upper edge of the second sidewall of the rail andthe structural component comprises applying a second fillet seal.
 4. Themethod of claim 1, wherein the bonding agent is injected into thechannel prior to positioning the structural component at least partiallyinto the channel such that the structural component rests on eachspacer, the method further comprising: removing excess bonding agentabove an upper edge of the first sidewall of the rail and above an upperedge of the second sidewall of the rail.
 5. The method of claim 1,wherein injecting the bonding agent into the channel comprises:injecting the bonding agent into the second gap between the structuralcomponent and the first sidewall of the rail; and injecting the bondingagent into the third gap between the structural component and the secondsidewall of the rail.
 6. The method of claim 1, further comprising:positioning a first plurality of removable spacers between the firstsidewall of the rail and the structural component; and positioning asecond plurality of removable spacers between the second sidewall of therail and the structural component.
 7. The method of claim 6, furthercomprising: removing the first plurality of removable spacers and thesecond plurality of removable spacers prior to injecting the bondingagent into the channel.
 8. The method of claim 1, wherein the bottomsurface of the rail includes a plurality of through holes, the methodfurther comprising: (i) sealing an upper edge of the first sidewall ofthe rail to the structural component; (ii) sealing an upper edge of thesecond sidewall of the rail to the structural component; (iii) injectingthe bonding agent into a first through hole of the plurality of throughholes such that the bonding agent exits an adjacent second through holeof the plurality of through holes; (iv) sealing the first through hole;and (v) repeating steps (iii) and (iv) such that each of the pluralityof through holes have been injected with the bonding agent and each ofthe first gap, the second gap, and the third gap includes the bondingagent.
 9. The method of claim 8, further comprising: applying a firstfillet seal between the upper edge of the first sidewall of the rail andthe structural component; and applying a second fillet seal between theupper edge of the second sidewall of the rail and the structuralcomponent.
 10. The method of claim 8, wherein the plurality of throughholes are interspaced evenly between the plurality of blind holes on thebottom surface of the rail.
 11. The method of claim 1, whereinpositioning a spacer in each of the plurality of blind holes comprisespositioning each spacer such that the longitudinal axis of the topportion of each spacer is positioned in a flow direction of the bondingagent when the bonding agent is injected into the channel.
 12. A systemfor bonding a structural component to a rail, the system comprising: arail including a bottom surface, a first sidewall extending from thebottom surface, and a second sidewall extending from the bottom surfaceto thereby define a channel, wherein the rail further includes aplurality of blind holes defined in the bottom surface; a plurality ofspacers each including a stem and a top portion extending substantiallyperpendicular to the stem, and wherein the stem of a given spacer of theplurality of spacers is configured to be positioned in each of theplurality of blind holes such that a longitudinal axis of the topportion of each spacer is parallel to a longitudinal axis of thechannel; and a structural component configured to be positioned at leastpartially into the channel such that the structural component rests onthe top portion of the plurality of spacers.
 13. The system of claim 12,wherein each of the plurality of spacers comprises a first material,wherein the structural component comprises a second material that isdifferent than the first material, and wherein the first material issofter than the second material.
 14. The system of claim 12, wherein thetop portion of each of the plurality of spacers includes a top surface,a bottom surface opposite the top surface, a first side surface, and asecond side surface opposite the first side surface, and wherein each ofthe top surface, the bottom surface, the first side surface, and thesecond side surface are substantially flat.
 15. The system of claim 12,wherein the bottom surface of the rail further includes a plurality ofthrough holes interspaced between the plurality of blind holes on thebottom surface.
 16. The system of claim 12, wherein the stem of each ofthe plurality of spacers includes a first side, a second side oppositethe first side, a third side, and a fourth side opposite the third side,wherein the first side and the second side are substantially flat andare parallel to the longitudinal axis of the channel, and wherein thethird side and the fourth side have a radius of curvature correspondingto a diameter of each of the plurality of blind holes.
 17. The system ofclaim 12, further comprising: a first plurality of removable spacersconfigured to be removably positioned between the first sidewall of therail and the structural component; and a second plurality of removablespacers configured to be removably positioned between the secondsidewall of the rail and the structural component.
 18. The system ofclaim 12, wherein the structural component comprises an aircraft canopy,and wherein the rail comprises a canopy rail.
 19. A method for bonding astructural component to a rail, the rail including a bottom surface, afirst sidewall extending from the bottom surface, and a second sidewallextending from the bottom surface to thereby define a channel, themethod comprising: positioning a bonding agent in a plurality of blindholes defined in the bottom surface of the rail; (ii) positioning aspacer in each of the plurality of blind holes, wherein each spacer hasa stem and a top portion extending substantially perpendicular to thestem, and wherein the stem of the spacer is positioned in each of theplurality of blind holes such that a longitudinal axis of the topportion of each spacer is parallel to a longitudinal axis of thechannel; (iii) positioning the structural component at least partiallyinto the channel such that the structural component rests on eachspacer, wherein a first gap is defined between the structural componentand the bottom surface of the rail, wherein a second gap is definedbetween the structural component and the first sidewall of the rail, andwherein a third gap is defined between the structural component and thesecond sidewall of the rail; (iv) positioning a first plurality ofremovable spacers between the first sidewall of the rail and thestructural component; (v) positioning a second plurality of removablespacers between the second sidewall of the rail and the structuralcomponent; (vi) sealing an upper edge of the first sidewall of the railto the structural component while simultaneously removing the firstplurality of removable spacers; (vii) sealing an upper edge of thesecond sidewall of the rail to the structural component whilesimultaneously removing the second plurality of removable spacers;(viii) injecting the bonding agent into a first through hole of aplurality of through holes in the bottom surface of the rail such thatthe bonding agent exits an adjacent through hole of the plurality ofthrough holes; (ix) sealing the first through hole; and (x) repeatingsteps (viii) and (ix) such that each of the plurality of through holeshave been injected with the bonding agent and each of the first gap, thesecond gap, and the third gap includes the bonding agent to thereby bondthe structural component to the rail.
 20. The method of claim 19,further comprising: applying a first fillet seal between the upper edgeof the first sidewall of the rail and the structural component; andapplying a second fillet seal between the upper edge of the secondsidewall of the rail and the structural component.